Modern Methods of Construction - 2020 Quarterly Review QR1 - Robert Bird Group
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QR1
Quarterly Review
2020
Modern Methods of
Construction
2
3
A challenge ahead for the
construction industry
Overview of Productivity improvement over time
Manufacturing
Productivity (value added per worker), real, $2005 Construction
105
100
95
90
85
80 1.7x
75
70
65
60
55
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012
It is now widely recognised that, in the last decades, the construction industry has failed to achieve a
technological evolution in line with most if the other manufacturing industries. This has led to a significant
shrinkage in efficiency and profitability that is straining the construction industry and is at the heart of the housing
crisis both in terms of delivery and affordability.
As highlighted by the report from the UN special rapporteur on adequate housing, despite the economic
recovery, adequate and affordable housing is increasingly out of reach to hundreds of millions of people.
Today, approximately 900 million people are living in “informal settlements” without the security of tenure -
entire communities that have grown up in slum-like conditions. Rates of homelessness are raising even in the
richest countries in the world, including Europe and USA.
These issues sum up to the critical workforce conditions and workers health and safety that, despite the
improvements, make the construction industry among the most (if not the most) unsafe industry,.
In the 30 years between 1959 and 1988, 7,449,160
houses were built in England, against only 3,328,850.
between 1989 and 2018.
Construction Industry accounts for approximately 6% of world’s global GDP but
contributes for 25- 40% of the world’s total carbon emission.
30% of global greenhouse gas emissions are attributable to buildings.
More efficient construction and building use will help significantly in tackling the climate
emergency
Off-site manufacturing, including modular and componentised design,
is establishing itself as one of the disruptor to the construction industry
and a potential key contributor to resolving these issues.
4
Modular Market Snapshot
“Modular Construction could claim $130
billion of market by 2030 in U.S. / Europe
at moderate penetration, delivering annual
cost savings of $22 billion”
When appropriately utilised, “Modular
construction can cut schedule by 20-50%
and construction costs by 20%”
McKinsey & Company. (2019). Modular construction: From projects to products.
Together, building and construction are responsible for 39% of all carbon emissions in the world, with
operational emissions (from energy used to heat, cool and light buildings) accounting for 28%. The remaining
11% comes from embodied carbon emissions, or ‘upfront’ carbon that is associated with materials and
construction processes throughout the whole building lifecycle. However, despite the targets, in the last
10 years the construction industry has not managed to reduce their carbon emission. (source: World Green
Building Council)
The recent spotlight on the global climate emergency brought fresh energy and interest from the entire
construction leadership to embrace the changes required to reduce the industry impact on the Planet. Many
companies are now targeting net zero operational carbon goals in the next years.
In 2019, the past seventeen Stirling Prize winning UK Architects made a declaration on
www.architectsdeclare.com, signing up to the aim of commissioning and designing buildings, cities and
infrastructures as indivisible components of a larger, constantly regenerating and self-sustaining system.
Robert Bird Group, together with many other engineering practices have since signed a similar declaration of
Climate and Bio-diversity Emergency, undertaking to change the way they work. RBG is fully committed to
the challenge of reducing the environmental impact of our industry across all the regions.
The use of more sustainable materials, developing more industrialised and efficient construction processes
leveraging on off-site manufacturing opportunities and using digital and parametric design tools will be the
key to achieve this ambitious goal of a construction industry revolution towards a more sustainable, carbon
free environment.
5
RBG’s Integrated Approach
Optimising the Design and
Construction Process
RBG’s target is to minimise the energy involved in the construction process. We believe that this can be
achieve by working in three key areas.
Optimisation Of The Materials
Just-enough material. Use of latest digital and parametric design technologies to optimise our design and avoid the
use of extra material where not necessary
Intelligent standardization. Introduction of standardization in the design of those items where economy of scale and
large repetition can deliver value.
Waste reduction. In depth knowledge of the manufacturing process to allow for a design that is truly optimised for
manufacturing, reducing material waste.
Minimise temporary works. “Design for Delivery” is one our core philosophies. Material optimization shall look at the
entire building lifecycle, including temporary works required during construction or dismantling of the building. The
best temporary structure is the permanent structure.
Optimisation Of The Design Process
Integrated design process. Optimum design integration between design disciplines such as architecture, MEP and
structure is the key to an increased area and volume efficiency in the design. The use of full BIM coordination (Revit
360) and bespoke BIM audit tools allow RBG to monitor the building efficiency and focus on those areas where further
design iterations are required.
Optimization of off-site / on-site construction. Early stage definition of which elements are best manufactured on
site is key to coordinate design and deliver best value to the Client. RBG have developed an off-site manufacturing
workflow to identify which items shall ideally be manufactured off-site to achieve an optimum design and construction
efficiency.
Design for Procurement. Good design should respect the marketplace of the project while also looking at
appropriately stretching the available supply chain to deliver an efficient project. RBG have intimate knowledge of
the marketplace and supply chain and use various techniques depending on the circumstances. These range from
early supply chain engagement or the use of manufacturing agnostic design delaying the need for supply chain
engagement while still resolving risks.
Optimisation Of The Construction Process
From construction to assembly. Pre-manufacturing of components (structural and non), either 1D, planks or volumetric
components, allows the optimization of the construction process, with a reduced programme on site and reduced
labour requirements, with significant H&S benefits.
Integrated construction process. Off-site manufacturing also opens opportunities to integrate the installation of
structure, façade and services at the same time. Construction sequence can be defined in order to allow the installation
of services and façade while the structure is being built, allowing an early installation of the fit-out elements.
6
Workflow for off-site manufacturing
Is the Construction of an element:
• Labour Intensive
• Material Intensive
• Slow/on the critical path
• Environmental Impacting
NO YES
Can it be manufactured
BUILD ON SITE
Off-site?
NO
YES
Is it transportable to site?
NO YES
YES
Can it be broken down MANUFACTURE OFF-SITE
to smaller components?
NO
Our Goal:
Delivering Value to our Clients
• Sustainability
• Lower Cost
• Higher Quality
• Faster Construction
• Safer Construction
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A long history of Modular
Construction and DfMA
oriented design
Robert Bird Group modular experience started in Australia where Unitised Building (UB®), operated under
licence by the Hickory Group, worked together with Fender Katsalidis (architects of the UB® System) and Robert
Bird Group (engineers of the UB® System) to deliver an innovative structural building technology system.
The UB system is essentially a structural steel frame infilled with light-weight foamed cement to provide fire
rating, acoustic, and thermal insulation. Structural concrete is limited to a 50mm wearing screed on the floor
panels.
The resultant building structure weighs 40% of a normal reinforced concrete structure.
Robert Bird Group was responsible for the design of all the structural elements, including the module to module
connection systems.
The benefit of the UB™ System was unprecedented design flexibility, façade and structural configurations, with
no fixed module height or width. The system could adapt to the specific design features of any given project,
allowing it to follow, not dictate, architectural design.
The system was also developed as a panelised solution.
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9
Crowne Plaza Extension
A new Hotel in 26 days
Crown Plaza Hotel extension is a 10 storey development next to Changi Airport, Singapore. The extension
comprises 243 guest rooms and the total building area is 10752m2. The hotel component of the extension
from Level 1 to 9 is constructed with UB RUSH modules. The UB modules are constructed off a conventional
reinforced concrete transfer slab at Level 1. The concrete lift core runs in a full building height as a major
structural stability element.
The volumetric modular approach allowed a very fast-track construction programme. The 252 modules
were installed in only 26 days, with practical completion achieved only 3 months after the last module was
installed.
Lightweight concrete was used for the first time on this modular project to achieve better acoustic and fire
property, without major impact on transportability and installation logistics. In terms durability, inspection
hatches are installed at every 3 floors.
10Project Summary
• 10 Storey Building;
• Extension to existing Crowne Plaza Hotel, Changi Airport, Singapore;
• Architects: WOHA, Singapore;
• Main Contractor: Dragages, Singapore;
• 243 Guest Rooms;
• 252 Modules;
• 26 days to install, installed by Unitised Building
• Modules installation completed in March 2016
• Project construction completed in July 2016
11Setting up a factory
(Sparkford Road case study)
Sparkford Road Project is a student accommodation building located in Winchester, UK. The
structure is a hybrid of in-situ concrete frame and hot rolled steel modular frame. The building is arranged
over five floors including one storey basement. The building consists of common areas such as gym and
wellness areas at basement and ground floor and 96 student rooms made of volumetric steel frames. The
modules come fully fitted on site and are assembled together via bolted connections.
RBG assisted the Client in setting up a new manufacturing facility.
RBG have has developed our own modular systems which haves hot rolled steel frame, self-centering
connections and cold formed steel infill for floors, walls and ceilings. This can be used for residential and
hotel projects directly and with some adaptation to commercial developments.
Foundations and enabling works can be procured with confidence and decoupled from the modular
supplier.
The modules can then be tendered in two simultaneous ways: in a traditional way, by engaging with
modular suppliers to deliver the building using their proprietary product; in parallel, RBG modules can be
procured traditionally as a steel frame package, fit out package and traditional main contractor contract that
oversees the fit out, transport, erection and finishing of the modules. All that is needed is to lease a flat floor
warehouse in a convenient location near the fit outfit-out workforce.
The second route was selected by Stelling Modular for this project.
This unique approach guarantees procurement flexibility: both traditional contractors and modular
manufacturers can deliver the building and no specific commitment is required from the Client before
tender stage.
12RBG also provided construction engineering services to the client by developing the proposed module
installation sequence and optimizing the crane location in relatively congested site. The definition of an efficient
construction sequence was key to ensure buildability. Bespoke installation guidance notes were issued for each
module which included a kit of parts required to come with the module to complete the installation and facilitate
the module to module connections.
13Digital design & Digital tools
(Applied to modular & DFMA)
Modular buildings are perfectly suitable to embrace digital technologies. The rules and patterns that
generate efficient design suit a Data Driver Design approach. The Data can be translated to any drafting
or analysis software and can have a central source (excel or other database). It can lean on computation
design tools and techniques such as Genetic Algorithms, Generative Design and algorithmic processes.
The creation of a standard library of members/components and details can greatly automate the drawing
delivery, as well as speeding up production, assembly and reducing costs and risks.
Building 11
London
14Full Coordination: Available on the cloud
RBG are developing exciting digital tools which will allow clients instant access to Project model data, such
as steelwork tonnages, concrete volume and embodied carbon, as well as useful information from the model
such as heaviest framing element to inform crane strategy and design. This data will be available via a secure
client web login area.
RBG also use these tools internally to audit the models and ensure the BIM Data within our models meets our
internal BIM standards as well as any client specific EIR’s. We can also appraise our design efficiency and spots
errors and inefficiencies more easily than with traditional tools.
In 4-5 Sparkford Road, RBG have used BIM 360 Design, a cloud worksharing and design collaboration tool that
allows to have Revit models in the cloud. The Client and the Design Team can log in at any time and check the
model state and coordination.
This can also be used to effectively transfer information from the design team to the production lines.
15Parametric & Digital Design tools for
live & efficient Modular Design
RBG have created bespoke digital design workflows by building a digital twin to provide clear understanding
and mitigation of risks in the design phase.
RBG have fully integrated visual scripting tools such as Grasshopper and Dynamo and bespoke scripts using
coding in python and C++ into our design process.
For instance, RBG have developed a fully parametric componentized system in Grasshopper for a rectilinear
modular frame in which it enables the change of the configuration of column count/locations, bracing
configuration and secondary member configuration. When used in a script, this can be driven either through
Grasshopper sliders or can be driven through excel/database.
16Digital Twin & Construction Logistics:
Enabling MMC on Site
The study of site logistics is critical for the adoption of modern methods of construction. Since most elements
would be fabricated offsite, studies with regards to transport, lifting and installation sequence of prefabricated
elements could immediately indicate the feasibility of utilizing these methodologies. It is essential that these
studies should be carried out early at the design phase to ensure feasibility of the scheme for the existing site.
RBG’s construction engineering team have been involved in identifying most optimum crane locations and
installation sequence for Sparkford Road student accommodation modular project. Via the use of parametric
tools, an optimum crane location can enable additional programme and cost savings.
17Design for Lean
Manufacturing
Building 11
Building 11 forms part of the Royal Arsenal Riverside development in Woolwich, London. The building
is composed of two separate structures: Block A - an existing listed building and Block B a new built 5
story residential building formed of 48 steel structural modular units interlocked together to create 19
apartments. A system of central walkways connects the two blocks together.
Key innovations included using a hybrid frame of steelwork and CLT to create robust modules for this high
end residential development as well as providing a complex module to module connection detail which
required a particularly inventive design due to access constraints and other limitations. The modular
structure also allows for the shift in column positions at internal locations and setback at terrace level via
transfer beams within the modular ceiling and using the CLT ceiling panels as the floor at the terrace level.
The CLT panels were specifically chosen for the ceiling in order to provide sufficient stiffness and strength,
allow for the required ceiling height and contribute to the rigid diaphragm action at each level.
The frame was designed to suit the modular manufacturers production line, by enabling self-stable floor
and ceiling cassettes to be moved, rotated, lifted and fitted out with finishes prior to being assembled as
one 3D volumetric frame. This was achieved by innovative connection design that worked for both the
temporary and permanent case.
Bathroom pods and prefabricated risers were also incorporated within the modular frame, which were being
manufactured simultaneously in a separate facility to reduce fit out time, therefore additional allowance had
to be accommodated within the floor cassette to allow for the bathroom installation at a later stage.
The processes followed in designing this module required a mindset for lean manufacturing and
understanding of an efficient production line which eventually led to faster module fit out cycles that
achieved a very tight delivery programme. RBG produced the concept installation methodology and full
fabrication drawings for this system.
1819
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Seismic applied
to Volumetric
New Zealand experience
Around the globe, millions of people are affected by earthquakes every year and the increasingly use of
Prefabricated Prefinished Volumetric Construction (PPVC) in new builds must consider the seismic effects in
the overall response of the completed structures.
The steel frame that forms the box around the PPVC modules is complemented with floor, roof and walls. For
seismic design, the connection between the modules allow them to act together as a larger structure resisting
lateral loads.
Seismic actions depend heavily in the local seismic zone and the soil classification; however, this demand
can be reduced applying the “ductility” concept, which is typically achieved by selecting an element of the
structure (ductile link) capable of sustain large deformations without losing strength or stability.
Because each modular project has its own motivation and vision, the selection of the ductile link must
be carefully studied and coordinated with the project stakeholders, such as owner, architect and other
consultants, but most importantly, the module manufacturer, who also should be engaged at early stages of
the project.
The capacity and flexibility of the selected PPVC manufacturer will dictate the available options for the seismic
resisting system. Materials and workmanship must be carefully reviewed to comply with local building codes,
leading to innovative and bespoke solutions.
21Wakefield Street Hotel
Auckland, NZ
The Wakefield Street Hotel will be a 14-storey building with 2 basement levels. Lower levels of the building
house the reception lobby, hotel facilities, and car parking while the rest of the elevated floors comprise 190
hotel rooms.
Critical to success of the project was the client’s decision to adopt volumetric modular construction
from inception due to the faster speed of construction. The hotel layouts, the design, and construction
programmes were designed to suit modular procurement. The podium structures will be conventionally
built and a transfer structure at level 2 and 3 allows the structural system to transition to modular
construction above that. Insitu lift and stair cores provide lateral stability to the building.
Robert Bird Group are providing structural engineering services for the hotel project, including the design of
the modular system.
Project Value: Client:
NZD$40 million FourQ Ltd
Year Completed: Architect:
Ongoing asc architects
Metrics: Robert Bird Group
Modular Design in Seismic Region Services:
190 Hotel Rooms Structural Engineering
14 Levels Civil Engineering
2-storey RC Basement Volumetric Modular
Large transfer beams and slabs Construction
9,000m2 floor area
Sectors:
Hotel
2223
24
Component Based Design
Component-based design is not a new concept and it is surely not a prerogative of the construction industry.
In essence, Component Based Design is the practice of splitting a product into smaller, more manageable
parts. The benefit of this approach is that, by combining componentisation with intelligent standardisation, the
production of each part can be industrialised, leading to significant savings in the component production cost
and in the assembly speed.
RBG have been active in the component-based design for a long time, working on multiple fronts, working with
developers implementing componentised solutions to deliver value to our client or with manufacturers assisting
them developing new systems.
The systems we have previously used or design include:
• Prefabricated concrete solutions;
• CLT and mass timber;
• Steel/concrete + CLT hybrid solutions;
• Panelised systems (including concrete or SFS solutions);
• Prefabricated MEP services;
• Prefabricated plant-room systems;
• Design of bathroom pods;
• Development of proprietary systems, such as Verteka®.
In RBG, we consider DfMA, Digital and Parametric Design as essential tools to deliver the levels of flexibility and
standardisation that are essential factors for a successful componentised solution.
As an example, RBG have developed an algorithm that optimises the use of precast plank typologies for
residential floorplates. By using genetic algorithms, the script is able to explore thousands of alternatives and
converges to the optimum solution of as fewer plank types as possible based on specific parameters such as
width, length, weight or a combination. In this case, fewer planks means an optimised fabrication cost. However,
the optimisation goal can be selected together with the Manufacturer or the Client to suit the specific design
case.
25A precast approach to
residential.
190 Strand
One of the projects where RBG have used extensively a component-based design approach is “190 The
Strand”. The project is a high-end residential development in central London, including five linked private
accommodation blocks over a shared basement that varies with the slope of the site. An additional separate
block provides affordable housing.
All the elements of the structural frame – flat slabs, columns and the core walls - are formed of precast
concrete, utilising Laing O’Rourke’s patented “Explore” products.
The component-based approach, with each element delivered on site ‘just-in-time’ and immediately installed,
allowed a quicker construction programme and a reduction in site deliveries, in a very congested area of
London.
In terms of BIM, the precast model was produced using the LOR product book which provided the Revit families
for the floor planks, columns and twin walls. This model was used to prepare drawings for locating the various
precast elements on site and which were read together with schedules detailing the various design parameters
like element reinforcement, dowels type, joint bars etc. RBG also developed a colour-coded 3D graphical
documentation model to assist the fabricator with the component production workflow. This allowed for time
saving both on/off site and improved quality control.
26190 The Strand
London
2728
Relationship with supply
chain around the world
In addition to developing in-house systems, RBG have worked with some of the best
modular and component manufacturer around the world. Using our digital design tool, we
are able to design our developments to suit multiple manufacturing solitions.
We call this Manufacturer Agnostic Design (M-A-D). MAD uses the appropriate level of BIM
to provide a component-based system that can be competitively tendered from a range
of suppliers. The principles of DfMA are maintained and integrated with VDC techniques
and safety by design approaches. Preliminary logistical considerations are also taken into
consideration such as manufacturing logistics within the factory, transportation, lifting and
any other critical stage of the construction process.
Coupled with digital prototyping, data repository sets, quantity assessments and the use of
product catalogues of standard parts and sub-assemblies, we believe that M-A-D provides
clients with the ability to competitively procure DfMA without the compromises normally
involved with the choice of a particular product suite or approach.
29CIMC Modular Building
System
Baxter Road
Currently Robert Bird Melbourne office have been appointed by Well Smart Investment Holdings to carry
out two modular projects in Sydney and Whitsunday.
The project (18160M) in Sydney is located at 40 -54 Baxter Road, Mascot, adjacent to the Sydney Airport.
The development is an 8-storey hotel development with a ground floor entry lobby, restaurant and staff
amenities. Levels 1-7 comprise 230 hotel rooms and the total floor area of 7885m2. The estimated project
construction cost is 22 million. The hotel component of the development is constructed with CIMC
Modular Building System.
30The modular tower will be constructed off a conventional post tensioning concrete transfer deck at Level
1. The concrete lift and stair cores only run up to Level 1. The CIMC building modules from Level 1 to 7 are
stand along.
The CIMC Modular structure is derived from the shipping container system. It consists of the corrugated
metal wall sheeting welded to the steel frames, the lightweight floor structure and the metal roof
structure. The floor structure is formed with 2x20 thick CFC sheets fixed on the cold form floor joists. The
roof structure is formed with 1.6 steel sheeting supported by the cold form rafters. All steel members are
welded on the production lines so that the system has excellent performance in the structural stiffness and
strength.
The corrugated wall sheeting in the longitudinal direction performs as shear wall to resist the lateral loads.
The portal frames in the cross direction are the stability elements due to the full glazing facades.
31www.robertbird.com
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